1 PDF

Section E Hydraulics Section E
i i
Contents Page No.
Schematics
Schematic Hydraulic Circuit 3-1
Spool in Neutral 3-3
Single Spool Operation (Arm/Boom/Bucket/Offset) 3-5
Two Spool Operation - Multi Functioning 3-7
Travel Operation 3-9
100% Swing Brake 3-11
50% Swing Brake 3-13
Swing Operation 3-15
Cross Line Relief Valve 3-17
Swing Reduction Gear Oil Recycling 3-18
Dozer Operation 3-19
JZ 70 Pump Theory 3-21
Anti Cavitation 3-23
Pressure Testing 4-1
Fault Finding 5-1
Hydraulic Pump
Dismantling and Assembly 24 - 1
Machine Valve Location 25 - 1
Remote Control Valve (Services)

Introduction 26 - 1
Operation 26 - 3
Maintenance Specifications 26 - 7
Control Valve
Precautions During Use 30 - 1
Pilot Supply Valve

Operation 60 - 1
Dismantling and assembly 60 - 2
Pilot Line System 60 - 3
9803/6030 Issue 1
ii ii
Contents Page No.
Hydraulic Rams
Precautions During Use 71 - 1
Bucket Ram Removal and Replacement 72 - 1
Dipper Ram Removal and Replacement 73 - 1
Boom Ram Removal and Replacement 74 - 1
Offset Boom Ram Removal and Replacement 75 - 1
Blade Ram Removal and Replacement 76 - 1
Ram Piston Head Nut - Removal and Fitting 77 - 1
Torque Specifications 77 - 4
Rotary Coupling
Description 80 - 1
Operation 80 - 2
Removal 80 - 4
Replacement 80 - 4
Dismantling 82 - 4
Slew Motor
Hydraulic Motor Components 83 - 1
Reduction Gear Components 83 - 2
Hydraulic Circuit 83 - 3
Operation 90 - 1
Maintenance Specifications 91 - 1
Motor Assembly/Cylinder Assembly
Fault Finding 95 - 1
9803/6030 Issue 1
3-1 Schematics 3-1
Schematic, Hydraulic Circuit
Main Components
1 Pump
2 Valve - Main Control
3 Valve - Pilot Supply
4 Accumulator
5 Filter - Servo
6 Manifold
7 Valve - Hand Control, RH
8 Valve - Hand Control, LH
9 Valve - Foot Control
10 Valve - Foot Control
11 Valve - Dual Solenoid
12 Valve Shuttle
13 Valve - Changeover, Solenoid
14 Motor - Swing
15 Motor - Travel
16 Ram - Dozer
17 Coupling - Rotary
18 Ram - Bucket
19 Ram - Boom
20 Ram - Dipper
21 Ram - Offset
22 Coupling - 3/4”
23 Coupling - 1”
24 Filter - Return
25 Not used
26 Valve - Tap
27 Filter - Nephron
28 Valve - Check, 2.5 bar
29 Cooler - Oil
30 Filter - Return
31 Valve - Bypass
32 Strainer - Suction
33 Breather - Air
34 Tank - Hydraulic
35 Switch - Pressure, 5 bar
36 Ram - Dipper
37 Ram - Throttle
38 Valve - Proportional
39 Valve - Sequence
40 Valve - 3-Station, Solenoid
41 Valve - Changeover
42 Valve - Relief
9803/6030 Issue 1
3 -1A Schematics 3 - 1A
DOZER
15 15
BOOM CYLINDER ARM CYLINDER

100- 65-927 95- 60-878
Z=11 16 MIN.L 1383 MIN.L 1364
Z=84 TRACK LEFT TRACK RIGHT 20
314 314
bar bar 19
at
P1 P2 at
R/G
R/G
i=54.0 314 20l/min 20l/min 314 i=54.0
bar bar
at P2 P1 at 44 +
20l/min 20l/min
Dr
i=19.464
T1 T2 45 + 49
!
P
3 4 6
5 29.9/44.1
29.9/44.1
cc/rev cc/rev
1 7
43
Au Ps 8 2 Ps 23
? 48
Ad Ae *
45.5 F-5 D-6
cc/rev 18 ! #
190 Bar
at 73l/min 17 8 2 HAMMER OR
BUCKET CYLINDER
85- 55-668 AUXILLARY
1 7 MIN.L 1050
5 22
14 3 4 6
* #
#
41 #
LEFT Mu RIGHT A C
B A
B
Ad
G-6
+ A1 C1
Aa
B-8
@ B1
!
f g i m p b z t r
*
D-7 D-7 D-7 B-6
k
B-7 D-6 B-8 @ B-4 C-8
# 53
B-5
B1 b1 B2 b2 P2 B3 b3 P3 B4 b4 B5 b5 B6 b6 Ps1
B7 b7 B8 b8 B9 b9
2 190Bar
280/300 305 305 255 305 305 305
Bar Bar Bar Bar Bar Bar
Bar
39
37
* 42 #
pZ 3 #
10bar
1
u
D-4
100
4 2 4
Ps3
A P MESH
R 3 2
T
305 305 305 305 305 305 1

Bar Bar Bar Bar Bar Bar * #
38 24
A4 a4 A5 a5 A6 a6 A7 a7 A8 a8 A9 a9 Ps2
pN
P A1 a1 A2 a2 A3 a3 10
pi1
pi2
[BM] [AM] [LOW FLOW] [HAMMER]
[DOZER]
e h j n l Ab
@
o a 3.5Bar
D-6 D-7 D-7 B-6 [BKT] B-5 B-8 B-6 D-5
[SW] [TL] [TR] 54
Ac Ae s * q
u
@ B-8 G-7
+ B-4
!
# C-8
E-7
28 9
26 2.5Bar TRAVEL(L) TRAVEL(R)
EC PILOT T E e f g h i j BACKWARD FORWARD FORWARD BACKWARD

E-4 F-4 F-4 E-4 F-5 E-5
28 4
CT5
29
CT4 45
bar CT8
27 1
2.5Bar A A1 C1 A2 A3 A4 C2 A5 A6
CT2 CT7
10u D CT9
a y b w
0.5 3 10 E-5 C-8
@ F-5 C-8 @
bar bar
2
33 4 2 1 3 12
CT6 IN OUT RIGHT LEFT 1 2 T P 4 3
26
C 35
bar B1 S1 S2 B2 B3 B4 S3 B5 B6
CT3
CT1
34 0.3Bar 0.05Bar
A P /
4 PV
3 8 P T
300cc 15 BAR ARM SWING
PRE CHARGE
30
10 51
1.03bar
5Bar 35 5Bar 35 @ @ @ @
P8 T8 P7 T7 P6 T6 P5 T5
10 OUT v w x y
150MESH IN B-5 D-6 B-5 D-5
T4 47 @
32 Pg1 D
A1 B1 A2 B2
P4
31
6 P T P1 T1 P2 T2 P3 T3 BLADE HY
D
M 1.03bar T1 13 T2
@ F-6
z 12 Ac
@
52 DOWN UP E-5
Pi
P1 P2
s t
5 Aa Ab
E-6 F-6 F-5 E-5
BOOM P T BUCKET
ISUZU 4JG1 @ @
q r
44KW @2300 rpm C1 C2 E-6 F-6
100MESH
11 !
9 10
C1 C2 C3 *
1 P T 2 40 #
6 7 8
7 o p 10
E-6 F-6
Dr S P1 P2 DOWN UP OPEN CLOSE
1
4 2 1 3
T1 T2 P1 P2
k v l x m n
F-5 C-8 E-5 C-8 F-5 E-5
@ @ T1 T2
MONOBOOM
A416330 (331/22982)
9803/6030 Issue 1
3 - 2A Schematics 3 - 2A
DOZER
15 15
ARM CYLINDER
BOOM CYLINDER OFFSET BOOM
100- 65-927 95- 60-788
Z=11 16 MIN.L 1383 MIN.L 1255
Z=84 36
314 TRACK LEFT TRACK RIGHT 314
bar bar 19
at P1 P2 at
R/G
R/G
i=54.0 314 20l/min 20l/min 314 i=54.0
bar bar
at P2 P1 at 46 +
20l/min 20l/min
Dr
i=19.464
T1 T2 45 +
49
P
3 4 6
5 29.9/44.1
29.9/44.1
cc/rev cc/rev
1 7
43
Au Ps 8 2 Ps
?
Ad Ae 48
45.5 F-5 D-6
cc/rev 18
190 Bar
at 73l/min 17 8 2 BUCKET CYLINDER
85- 55-668 OFFSET CYLINDER
1 7 MIN.L 1050 100- 55-415
MIN.L 830
5 4 6
14 3
21
LEFT Mu RIGHT
B A
Ad
G-6
+
Aa
B-8
@
f g i m p b z c t
D-7 D-7 D-7 B-6
k
B-7 D-6 C-7 @ D-4 B-4
B-5
B1 b1 B2 b2 P2 B3 b3 P3 B4 b4 B5 b5 B6 b6 53
B7 b7 B8 b8 B9 b9
50
280/300 305 305 255 305 305 305
Bar Bar Bar Bar Bar Bar Bar
37
pZ
u
E-4
100
4
Ps3
A P MESH
R 3 2
T
305 305 305 305 305 305 1

Bar Bar Bar Bar Bar Bar
38 A4 a4 A5 a5 A6 a6 A7 a7 A8 a8 A9 a9 Ps2
pN
P A1 a1 A2 a2 A3 a3
pi1
pi2
[BM] [AM] [OFFSET] [LOW FLOW]
e h j n l Ab o [DOZER] a 54
D-7 D-7 B-6 [BKT] B-5 B-8
@ B-6 D-5
D-6
[SW] [TL] [TR]
Ac Ae d s
u
@ B-8 G-7
+ D-4 B-4
E-7
28 9
26
TRAVEL(L) TRAVEL(R)
2.5Bar c d
F-6 D-6
EC PILOT T E e f g h i j BACKWARD FORWARD FORWARD BACKWARD

28 % 13 A2 A1 B2 B1 E-4 F-4 F-4 E-4 F-5 E-5
4 5
CT5
29 CT4 45
27 bar CT8
1
A
2.5Bar CT7 P1 T P2 A1 C1 A2 A3 A4 C2 A5 A6
CT2
10u D CT9
a y b w
0.5 3 10 E-5 C-8
@ F-5 C-8 @
bar bar
2
33 4 2 1 3 12
26 CT6 IN OUT RIGHT LEFT 1 2 T P 4 3
C 35
bar B1 S1 S2 B2 B3 B4 B5 B6
CT3
34 0.3Bar 0.05Bar CT1
A PV P
4
300 CC PRE 3 8 P T
CHARGE 15 BAR ARM SWING
30
10
51
1.03bar
/
@ @ @ @
P8 T8 P7 T7 P6 T6 P5 T5
10 OUT 35 35 v w x y
150MESH IN B-5 D-6 B-5 D-5
T4
5 BAR 47 @
32 Pg1 D 5 BAR
A1 B1 A2 B2
P4
31
6 P T P1 T1 P2 T2 P3 T3 BLADE D
Y
H
M 1.03bar T1 13 T2
z
@ F-6 12 Ac
@
52 DOWN UP E-5
Pi
P1 P2
s t
5 Aa Ab
D-6 F-6 F-5 E-5
BOOM P T BUCKET
ISUZU 4JG1 @ @
44KW @2300 rpm C1 C2
100MESH
11 !
9 10
1 P T 2
7 o p 10
F-6 E-6
Dr S P1 P2 DOWN UP OPEN CLOSE
1 OFFSET BOOM
4 2 1 3
A416340 (331/22983)
T1 T2 k v l x m n
F-5 C-8 E-5 C-8 F-5 E-5
@ @
9803/6030 Issue 1
3-3 Schematics 3-3
Control Valve - Spool in Neutral (Arm/Boom/Bucket/Offset)
A
B
C
RETURN FROM SERVICE
D
E
280/300
pZ Bar
A NEUTRAL GALLERY
pi2
P pN Pi1
Port D
A354050
9803/6030 Issue 1
3-4 Schematics 3-4
Control Valve - Spool in Neutral

(Arm/Boom/Bucket/Offset)
Key
A High pressure feed

B Load sensing pressure
C Return pressure/tank
D Negative control
E Servo pressure
When the spool is in the neutral position (no service

selected) the oil from the pump (port D) flows into the valve
block via port P.
1 The oil enters the flow control valve and pushes the
spool against the spring. The oil then flows through the
orifice to tank.
2 Oil also flows from the valve block (port pN) back to the
pump to hold the pump on minimum flow.
3 The oil supply to port P also flows through the neutral

gallery of the valve block, ready to supply the spools as
required.
9803/6030 Issue 1
3-5 Schematics 3-5
Control Valve - Single Spool Operation
RETURN FROM SERVICE

A
B
C
D
E
A NEUTRAL GALLERY
A
B COMPENSATOR 280/
pZ 300
C COMPENSATOR CHECK VALVE bar
pi2
C
B
R
P pN piN Ps2
TO A SERVICE
PORT D
A354060
9803/6030 Issue 1
3-6 Schematics 3-6
Control Valve - Single Spool Operation

(Arm/Boom/Bucket/Offset)
Key

D Negative control
E Servo pressure
1 When the single service is selected (the arm is used

here as an example), 40 bar servo pressure moves the
spool into the working position.
a The oil from the neutral gallery flows through the

spool and opens a check valve to allow oil to flow to
the arm ram.
b Oil flows to the compensator and, with the

assistance of the compensator spring, keeps the
compensator valve opened (as shown opposite).
c Oil will also open the compensator check valve and

through the Load Sensor (L/S) and exit through port
Ps2 on the valve block.
d The oil in the L/S line can also be seen at the

opposite side of the compensator. The compensator
will not move as the spring pressure on the opened
side will assist the oil pressure and stop it from
moving.
e Oil from the Ps2 port will then be seen back at the
valve block in port pi2. This pressure will then with
the assistance of the spring on the flow control
move the valve over and stop the main pressure
from the pump returning via port pN and holding the
pump on maximum flow.
2 The oil returning from the arm ram enters the spool and
goes to tank via two paths:
a On the first path the oil crosses the spool and then
the compensator to return to tank.
b On the second path the oil crosses the spool and

then crosses back via another cut out in the spool
to return to tank.
9803/6030 Issue 1
3-7 Schematics 3-7
Control Valve - Two Spool Operation - Multi Functioning
A
B COMPENSATOR
B
C D RESTRICTOR
D
E
B1 b1 B2 b2
pi1 A1 a1 A2 a2
A356840
9803/6030 Issue 1
3-8 Schematics 3-8
Control Valve - Two Spool Operation -

Multi Functioning When operating more than one service at a time, the
following will be seen in the valve block.
Key
The first service will work as per single service operation, but
A High pressure feed when a second service comes into use:
C Return pressure/tank 1 The service that is of a higher pressure will also have a
D Negative control higher L/S pressure.
E Servo pressure
1.1 The higher L/S pressure will act against the
When two services with different working pressures are compensator of the lower pressure compensator and
operated at the same time, the valve block circuit move this valve to the restricted position.
compensates as follows to ensure smooth independent 1.2 Because this valve is now restricting the flow of oil the
operation of both. pressure in this service will increase to the same
pressure in the higher pressure service.
The service with the higher working pressure has a higher
load sensing pressure. Since the load sensing circuit is
common to both circuits it adopts the higher level. Acting
For example.
against the compensator of the lower pressure circuit, which
overcomes the combined spring/working pressure forces
Boom working pressure = 200bar
and moves the compensator into its restricted position.
Boom L/S Pressure = 200bar minus 5bar at L/S orifice.
The restrictor now introduced into the circuit of the lower
Arm working pressure = 150bar
pressure circuit causes its pressure to increase to the same
Arm L/S pressure = 200bar minus 5bar at L/S orifice.
level as that of the higher pressure circuit.
Now Arm working pressure will increase up to 200bar.
When either of the circuits is deselected the valve block
reverts to single spool operation mode.
9803/6030 Issue 1
3-9 Schematics 3-9
Travel Operation - Low Speed DOZER RAM
TRAVEL MOTOR LH TRAVEL MOTOR RH
284 P1 P2 284
bar bar
284 284
bar bar
P2 P1
T1 T2
i-54.0
29.9/44.1
cc/rev
F 29.9/44.1
cc/rev
Ps Ps
ROTARY COUPLING
A
B F HIGH SPEED SPOOL
C
D
E
305
bar
B2 b2 P2 B3 b3
280/
pZ 300
bar
pi2
CONTROL VALVE
R
305
bar
p pN pi1 A2 a2 A3 a3
A1 C1 A2 A3 A4 C2 A5 A6
HYDRALIC PUMP B1 S1 S2 B2 B3 B4 B5 B6
SHUTTLE VALVE
A354010
9803/6030 Issue 1
3 - 10 Schematics 3 - 10
Travel
Key

D Negative control
E Servo pressure
Travel - Low Speed

The travel spools are noticeably different than any other
spool in the valve block.
They are designed to allow oil from the travel motors to
vent directly back to tank when travel is not selected.
These spools are called travel or motor spools.
Apart from the travel spools having a permanent drain to
tank when NOT selected they work in the same way as
any excavator or swing spool in the valve block.
Travel - High Speed
The only difference between low and high-speed travel is

that:
The high-speed solenoid will be selected (electrically) in
the pilot supply valve. A hydraulic signal from the
solenoid (port O) will supply servo pressure (40bar) to
the travel motor (port Ps) via the rotary coupling.
The high-speed spool in the travel motor will move into
the selected position. Main system pressure from the
selected spool in the valve block can now cross the
high-speed spool and force the swash plate of the travel
motor to move. The swash angle of the motor will
increase and so allow more oil through the travel motor.
(the more oil through the motor = higher speed but less
torque)
9803/6030 Issue 1
100% Swing Brake
SWING MOTOR
A
D
B
C
P
Au
EC PI2 T E
D
X A
Y
C
Mu
B A
A PV P
PILOT SUPPLY VALVE
X Swing Brake Solenoid
Y Swing Lock Solenoid
A358770
9803/6030 Issue 1
100% Swing Brake

Key
A Pump pressure
B Servo pressure
a When 100% swing brake is required then the swing

brake solenoid (part of the pilot supply valve) will be de-
energised and the swing lock solenoid (part of the pilot
supply valve) will be energised.
b With the swing lock solenoid energised then the oil in
the swing motor brake will be vented back through the
swing lock solenoid. The vented oil is then put to tank
giving 100% swing brake.
9803/6030 Issue 1
50% Swing Brake
SWING MOTOR
A
D B
C
P D
Au
EC PI2 T E
X A
D
Y
Mu
B A
A PV P
PILOT SUPPLY VALVE
X Swing Brake Solenoid
Y Swing Lock Solenoid
A358810
9803/6030 Issue 1
50% Swing brake

Key
A Pump pressure
B Servo pressure (40 bar)
D Servo pressure (10 bar)
a 50% swing brake is achievable by having the swing

brake solenoid energised and the swing lock solenoid
de-energised.
b Servo pressure (40 bar) in the pilot supply valve will pass
through the energised swing brake solenoid and via the
10 bar pressure reduction valve. The 10 bar pressure
will move the shuttle and travel to the swing motor
brake.
c The 10 bar at the swing brake gives 50% swing brake.
9803/6030 Issue 1
Swing Operation
SWING MOTOR A
B
Z=11 Z=84 C
D
D
B1 b1
P
Au
pZ
pi2
R
Mu
B A
P pN pi1 A1 a1 CONTROL VALVE
A1 C1 A2 A3 A4 C2 A5 A6
HYDRAULIC PUMP
B1 S1 S2 B2 B3 B4 B5 B6
EC PI2 T
SHUTTLE VALVE
B
D A
A2 A1 B2 B1
C 40
P1 T P2
A PV P
PILOT SUPPLY VALVE CHANGEOVER SOLENOID
A356830
9803/6030 Issue 1
Swing Operation
Key

B Servo pressure (40 bar)
D Negative control
a When swing is operated the swing brake and swing lock

solenoids are de-energised. This allows full servo
pressure to the swing motor and fully releasing the
swing break.
9803/6030 Issue 1
Cross Line Relief Valve

The swing cross line relief valve is installed inside the
swing motor to prevent the swing back when the swing is
stopped.
1 No swing (Figure 1)
The swing cross line relief valve is in neutral state.
2 Swing acceleration, during swing (Figure 2) Figure 1

When operating the swing, port H and port J are
connected through the small hole E the intermediate
chamber D and the small hole F. The oil flows out of port B C
J immediately. The high pressure oil enters into the A
back chamber of the poppet B. This causes the poppet D
to move towards the right side as in figure 2
3 Swing Braking (Figure 3)

E
When operating the swing brake from figure 2 status, G F
the motor is activated by the pump, with both ports H
and J locked. Figure 2
H J
The pressure changes from high pressure to low
pressure on port H and from low pressure to high
C
pressure on port J. Since port J is connected with the
intermediate chamber poppet B is pushed open. K L
B D
Port J, the intermediate chamber D and port H are
connected through the small hole F and the small hole E,
a small amount of oil flows out from port J to port H,
eventually the poppet C will seal on seat K and the oil
flow will be cut.
F
L
4 Swing Cross Line Relief Valve (Figure 4) Figure 3
H J
After stopping swing, the motor returns to the opposite
direction by the remaining pressure from Port J. There is
probably high pressure in port H. Since port H is M N C
connected with the intermediate chamber D, and port J B D
(connected through the small hole F and the small hole
E), a little oil flows out from port J to port H.
Because there is no close of pressure between port H E

P
and port J, the back shaking is reduced. F
The oil from the spring chamber on the back section of

the poppet B, and poppet C flows out through poppet N Figure 4 H J
and spring M via the control valve.
9803/6030 Issue 1
Swing Reduction Gear Oil Recycling
To aid maintenance, the drain oil from the motor section

is used as lubricating oil for the swing gearbox,
eliminating the need to replace the oil in the gearbox.
A Pressure Line
B Return Line
A E Decelerating Recycling Line
C
B C
D Filter
E Swing Motor
F Hydraulic Oil Tank
D G From Control Valve
H Oil Flow
J To Control Valve
K From Control Valve
L Without Oil Seal
M To Hydraulic Tank
F G
H
J
K
L
289490
9803/6030 Issue 1
Dozer Operation
DOZER RAM
INTERGRATED DOZER
A
RAM CHECK VALVE B
C
D
E
305
CONTROL VALVE
B8 b8 bar
CONTROL VALVE
280/
pZ 300
bar
pi2
M
R Ps2
305
bar
P pN piN A8 a8
M
M COMPENSATOR
A356850
HYDRAULIC PUMP
9803/6030 Issue 1
Dozer Operation
Key

D Negative control
E Servo pressure
1 When the single service is selected, 40 bar servo

pressure moves the spool into the working position.
a The oil from the neutral gallery flows through the

spool and opens a check valve to allow oil to flow to
the dozer ram.
b Oil flows to the compensator M and, with the

assistance of the compensator spring, keeps the
compensator valve opened (as shown opposite).
c Oil will also open the compensator check valve and

through the LS and exit through port Ps2 on the
valve block.
d The oil in the LS line can also be seen at the

opposite side of the compensator. The compensator
will not move as the spring pressure on the opened
side will assist the oil pressure and stop it from
moving.
e Oil from the Ps2 port will then be seen back at the
valve block in port pi2. This pressure will then with
the assistance of the spring on the flow control
move the valve over and stop the main pressure
from the pump returning via port pN and holding the
pump on maximum flow.
2 Before the service pressure enters the dozer ram a leak

off of service pressure crosses the integrated dozer ram
check valve to lift the return side check valve. This
allows the return side oil to pass through the open
check valve and return to tank via the control valve.
a The oil returning from the dozer ram enters the

spool and goes to tank via two paths:
b On the first path the oil crosses the spool and then
the compensator to return to tank.
c On the second path the oil crosses the spool and

then crosses back via another cut out in the spool
to return to tank.
9803/6030 Issue 1
Services not selected

A
B
C
D
Pg1 D
Min.
Min.
C
Flow
Max.
M
Pi
A
Dr S
A358780
Services selected
A
B
C
D
Pg1 D
Min.
Max.
Max. Flow
M C
Pi
Dr S
A358790
9803/6030 Issue 1
JZ 70 Pump Theory
Key
A Reduction in Negative Pressure

B Pump Pressure
C Oil Feed to Pump
D Return Pressure to Tank
Services not selected
Oil is delivered from port D into the control valve block

port P, neutral circuit pressure is regulated inside the
valve block to 30 bar by an orifice. Pump pressure is
always available to the spring side of the swash control
piston. This will hold the pump at maximum flow
position.
A negative control signal is generated in the control
valve block and sent to the pump at port Pi, and acting
on a plunger, the plunger A will select the summator
spool B against the spring tension. In turn this allows
pump pressure into the head side of the swash control
piston C. With 30 bar now in both sides of the swash
control piston, it will select against the spring, due to the
difference in surface areas, this will put the pump at
minimum flow.
Services selected
When a service is selected in the control valve block,

negative control pressure reduces proportionally, spring
force will now start to push the summator spool B back
to its original position, allowing pressure in the head side
of the swash control piston C to vent to tank. Pump
pressure in the spring side forces the control piston to
maximum flow position.
When the pump pressure increases on the small area of
the summator spool B, it has enough force to start to
select the summator spool again against the spring, and
thus reducing the pump flow and keeping the
horsepower constant. If the system pressure continues
to increase, pump flow will continue to reduce due to
the horsepower control.
9803/6030 Issue 1
Anti Cavitation
The regeneration check valve can also be called the anti-
cavitation check valve.
The services with anti cavitation are,

Boom down.
Bucket ram open.
Arm ram open.
Off set ram open.
Example of how the anti cavitation works.
When operating the boom down, the weight of the

attachments will assist the boom to fall so this will cause a
low pressure to be seen in the feed side of the ram.
If the pressure in the feed side of the ram falls below 2.5 bar
then the anti cavitation check valve will be forced open by
the 2.5 bar pressure in the tank line. The oil from the tank
line will then enter the spool and keep the service fed with oil
to stop the service from cavitation.
9803/6030 Issue 1
4-1 Pressure Testing 4-1
Pressure Testing - General
Confirmation of the oil Temperature
Confirm the oil temperature is between 45° - 55° C using a 5 Operate the bucket control slowly until it reaches one
thermometer. If the temperature is low use the following end of its travel and leave it there for 30 seconds.
warm-up procedure.
6 Operate the bucket control slowly to the other end of its
Warming-up Procedure travel and leave it there for 30 seconds.
7 Repeat steps 5 and 6 for 10 minutes to warm up the

1 Turn the Throttle Control to mid-range and make sure
hydraulic circuit.
the Work Mode Selection Switch is set to S.
8 Now operate the excavating controls three to five times
2 Press the One Touch Idle Switch.
in each direction to distribute warm hydraulic oil around
3 Run the engine until the Coolant Temperature gauge the system.
reads within the normal (green) range.
4 Set the Servo Isolator Switch to ON to enable the

hydraulic servo controls to be operated.
Pressure Measurement Measurement

Part Name bar (lbf/in2) Method Port
Main Relief 280 bar (4060 lbf/in2) Dipper Relief Pg1
Boom Port Relief Up 305 bar (4422 lbf/in2) Boom Up Relief Pg1
Down 255 bar (3698 lbf/in2) Boom down Relief Pg1
Bucket Port Relief Out/In 305 bar (4422 lbf/in2) Bucket Relief Pg1
Dipper Port Relief Out/In 305 bar (4422 lbf/in2) Dipper Relief Pg1
Swing Port Relief Left/Right 190 bar (2755 lbf/in2) Swing Relief Pg1
Dozer Port Relief Up/Down 305 bar (4422 lbf/in2) Blade Relief Pg1
Pilot Relief 34 - 44 bar (493 - 638 lbf/in2) Lever Neutral PI 2
Travel 300 bar (4350 lbf/in2) Travel Motor Stall Pg1
Offset 305 bar (4422 lbf/in2) Offset Stall Pg1
9803/6030 Issue 1
5-1 Fault Finding 5-1
Some problems which may occur in the hydraulic system are

listed below, either for the system as a whole or for
individual components
Symptom Possible Cause Action
1 Hydraulic System
a The hydraulic system is 1 The pump is defective. Check pump pressure and renew if
defective or does not defective.
operate at all.
2 Dirt is clogging the inside of the relief Dismantle and clean the relief valve.
valve.
3 The relief valve is defective. Strip and check the relief valve.
4 A ram is worn. Repair or renew the ram.
5 Negative pressure is low. Check circuit pressure.
6 A valve is cracked. Renew the valve.
7 A spool is not operating over its full Check the movement of the spool or the
stroke. operational linkage.
8 The oil level in the tank is too low. Replenish the oil.
9 Circuit filters are clogged. Clean or renew filters.
10 The circuit pipes are restricted. Check the piping.
2 Hydraulic Pump
a Oil is not discharged from 1 The tank strainer or intake pipe is Clean the strainer and clean the intake
the pump. blocked. pipe.
2 The end of the inlet pipe is above Replenish the oil tank.
the tank oil level.
3 One or more of the pump major Dismantle and inspect pump. Renew
components is damaged or the damaged components and reassemble
input shaft or coupling are defective. the pump. Renew shaft or coupling.
b Pump output is low. 1 The pressure does not increase Check hydraulic pump and control valve.
Hydraulic pressure because of problems with the Renew as required.
does not increase. hydraulic pump or control valve.
2 Internal leakage within the hydraulic Strip and inspect the hydraulic pump,
pump with excessive fluid drain from paying particular attention to sliding
pump drain port. surfaces. Repair or renew as necessary.
Reassemble the pump.
3 Air is being drawn into the pump Check tank oil level and strainer for
from the inlet side. clogging. Correct as necessary. If OK,
check tightness of pump inlet
connection.
4 Inlet resistance causing cavitation. Check correct oil . Check pump low
pressure inlet pipe for collapse. Renew
as required.
c The pump makes an 1 Oil level is low and the pump is drawing Check and replenish oil level. Run the
abnormal noise. in air. pump under no load to bleed air from the
hydraulic system.
9803/6030 Issue 1
2 Hydraulic Pump (cont'd)
2 Clogging of the tank strainer. Clean strainer. If strainer is severely

clogged, drain and flush hydraulic
system.
3 Oil temperature is too low or wrong Check correct oil for ambient
oil specification. temperature, see Fluids and Lubricants,
Capacities and Specifications, Section
3.
4 Coupling defective. Check shaft run out.
5 The pump is resonating with Check pump mounting bolts for

external equipment. tightness.
Tighten as required.
6 Internal damage to pump. Dismantle and inspect pump, paying

particular attention to bearings and
sliding surfaces.
d Engine overload 1 Regulator torque set too high. Adjust as necessary.

(engine speed very low
or engine stalled). 2 The servo flow within the regulator Remove the regulator from the pump and
is blocked or internal components check filter for blockage. Clean as
are seized. necessary. If filter OK, dismantle and
inspect regulator.
3 Pump is seized or worn. Dismantle and inspect pump, paying

particular attention to sliding surfaces.
Repair or renew as necessary.
Reassemble the pump.
e Oil leakage. 1 Internal leakage within the pump Dismantle and inspect pump, paying
causing oil seal damage and oil particular attention to oil seals and
leakage. sliding surfaces. Renew as
necessary, ensuring that lips of oil
seals are not damaged when installed.
2 Damaged or blocked drain pipe. Inspect and renew as necessary.
3 Control Valve
a A spool is sticking. 1 Oil temperature abnormally high. Check correct oil, see Fluids and
Lubricants, Capacities and
Specifications, Section 3. Check oil
cooler and grille for blockage.
2 The hydraulic oil is dirty. Clean the tank strainer. If strainer badly
clogged, drain and flush hydraulic
system.
3 The service pipe connection Check tightening torque.

is overtightened.
4 The valve housing was twisted Loosen retaining bolts and tighten to
during installation. correct torque figures.
5 Pressure too high. Check system pressure.
6 A spool is bent. Renew the control valve section.
7 A return spring is broken. Renew as necessary.
9803/6030 Issue 1
3 Control Valve (cont'd)
8 A return spring or cap is out of Remove the cap, check that the spring is
alignment. in the correct position. Refit cap and
torque tighten bolts.
9 Temperature distribution within Warm the entire system up before

control valve not uniform. using service.
b A spool does not move 1 Dirt is clogging the inside of the Remove the dirt (flush out the valve).
over its full stroke. valve.
c The dipper/boom falls 1 Oil is leaking past the ram/ boom Renew piston seals.
under load with the spool piston seals.
in neutral.
2 Oil is bypassing dipper/boom spool. Renew control valve section.
3 Oil is leaking past dipper/boom ARV. Remove ARV and clean housing seat
and relief valve seat. Refit ARV.
4 Main Relief Valve
a System pressure does 1 The main poppet, check valve poppet Remove MRV and dismantle.
not rise at all. or pilot poppet is sticking open, or dirt Inspect and clean all parts.
is caught in the valve seat. Assemble MRV, ensuring that
all parts slide freely. Refit the MRV.
b Relief pressure is unstable. 1 The pilot poppet seat is scratched or Remove MRV and dismantle.
the pilot piston is sticking with the Inspect and clean all parts.
main poppet. Parts worn. Renew damaged parts or remove
scratches with very fine emery cloth.
Assemble MRV, ensuring that all parts
slide freely. Refit MRV.
2 The lock nut and adjusting screw Tighten the lock nut and reset MRV
are loose. pressure.
c Oil leak 1 Worn 'O' rings. Remove MRV and renew 'O' rings.
9803/6030 Issue 1
24 - 1 Hydraulic Pump 24 - 1
Hydraulic Pump
9803/6030 Issue 1
Hydraulic Pump
9803/6030 Issue 1
Hydraulic Pump - Dismantling

Note: The hydraulic pump must be dismantled on a 79 19
workbench.
35 68
1 Clean the spline shaft, each port, and the pump body.
Remove the hydraulic oil from pump casing.
Before dismantling the pump make matching marks
between the cover 19 and the housing 35, the housing
35 and the servo case 79, the housing 35 and the return
cover 68.
This will assist in reassembly.
Remove the of return cover assembly 52 x 4

Loosen the four hexagon socket bolts 52 with an 8mm
hexagon wrench.
Remove the return cover assembly.
2 Remove the servo case assembly.
Loosen the four hexagon socket bolts 52 with an 8mm

hexagon wrench.
52 x 4
Remove the servo case assembly.
3 Mount the pump assembly on the workbench with

hexagon bolts. 42 x 4
Loosen the four hexagon socket bolts 42 with a 14mm
hexagon wrench.
Do not remove the bolts.
9803/6030 Issue 1
Hydraulic Pump - Dismantling (continued)

20 x 4 3
4 Remove the seal retainer. Place the pump with the shaft
up and loosen the six hexagon socket bolts 20 with an
2
8mm hexagon wrench.
5,6
Remove the bolts 20, the seal retainer 3 and the shims
5 and 6 from the housing. Use the tapped holes (M10)
35
on the seal retainer to assist removal.
Remove the oil seal 2 from the seal retainer 3 with driver
and hammer.
Do not reuse the oil seal after removal.
Remove the four hexagon socket bolts 42 with 14mm

hexagon wrench.
42 x 4
5 Removal of the housing assembly
Lift up the housing assembly slowly with a wire rope.
If the housing assembly will not separate easily, lightly

strike the surface of the housing with a plastic faced
hammer.
If the cylinder 14 and the port plate 16 pull up with the

housing 35, be careful not to drop the cylinder and the
port plate.
35
14
16
9803/6030 Issue 1

10
6 Make a matching mark between the return plate 10 and
the cylinder 14, separate the piston assembly 11 the 11x9
retainer 28, and the nine springs 13 from the cylinder 14.
Remove the cylinder 14, the port plate 16, the ring 31 28
the bush 33, the o-ring 15 and the three springs from
the cover 19.
13x9
Separate the 2 bushes 43 from port plate 16
Make a matching mark on piston hole of cylinder and

piston assembly to fit piston into the same hole when 14
reassembling.
16
32
43x2 33
34x3
15
19
7 Position the housing assembly 35 with the cover 9 on

the bench. Remove the outer race of toper roller bearing
7 and the shaft 1 from the housing. 7 1
35
9803/6030 Issue 1

8 Removal of the inner race of the roller bearing.
Position a gear puller at two places on the inner race of
the tapered roller bearing 7 and the spline end of the
shaft 1 and pull the inner race of the tapered roller
bearing.
9 Loosen the four hexagon socket bolts 12 with a 6mm

hexagon wrench, and remove the cover 9. Remove the
locating plug 27 with a 6mm hexagon wrench.
Separate the cam assembly from the housing 35, Be

careful not to damage the cradles 22 and 8 with the
cam.
35
27
12x4
10 Loosen the two screws 21 with a 3mm hexagon wrench, 21x2

and remove the cradle 22 and the cradle 8.
22 8
9803/6030 Issue 1

45x3 49
11 Dismantling the servo case assembly.
Loosen the four hexagon socket bolts 45 and 49 with a 46

6mm hexagon wrench and separate the servo cover 46
from the servo case assembly.
Remove the piston 47 from the servo cover 46. 47
12 Remove the rod assembly 75 (containing the piston 48, 48

the shims 50 the shims 81 the spring 78 and the spring
77 from the servo case 19. 50
78
81
Do not lose the shims 50 and the shims 81 (They are 77
used for horse power setting). 75
Remove the power piston assembly 59 (containing the 80 53

plate 60, the receiver 61, the snap-ring 74 and the bush
76 from the servo case.
Loosen the plug 53 with a 5mm hexagon wrench, and

remove the filter holder 55, and the filter 56 from the 56 55
servo case 79. 52
79
Do not loosen the nut 80 and the sleeve 52. (They are
used to set the maximum flow.) 76
74
59
60
61
13 Dismantling the return cover assembly 73
Remove the rod 73, the piston 72 and the spring 70

72
from the return cover 68.
Loosen the plug assembly 67 with a 36mm hexagon

wrench, and remove the plug assembly from the return 70
cover 68.
Do not loosen the nut 66. (It is used to set the maximum 68
flow.)
This completes the dismantling procedure.
69
67
66
65
9803/6030 Issue 1
Hydraulic Pump - Assembly

11
Before Assembly
Before reassembling, perform following procedure.
1 Check each part for damage caused by wear and tear or

dismantling. If damaged, remove scratches by rubbing
with ‘wet and dry’ sandpaper of appropriate coarseness.
Clean each part with clean washing oil and dry with an
air jet.
2 Replace the oil seals.
3 Lap the sliding contact faces of the piston assembly 11,

the port plate cw 16 and the cylinder 14 with very fine
paste on a flat surface.
4 When assembling, lubricate the sliding parts with

specified clean hydraulic oil.
5 When assembling, the piston assembly to the piston

hole of cylinder, make sure to fit each one back into the
original hole it occupied before disassembly.
6 Assemble the three springs 34, the bush, 33 the ring 32

16
and the o-ring 15 to the cover 19.
32
Apply grease to bushing holes of the port plate 16. 43x2
Assemble the two bushes 43 in the bushing hole of the 33
port plate 16. 15 34x3
19
When assembling, confirm the original position of the
port plate.
Suction Port
9803/6030 Issue 1
Hydraulic Pump - Assembly (continued)

10
7 Assembling the cylinder assembly
11x9
Insert the nine springs 13 in the spring holes in the
cylinder 14. Put the retainer 28 on the springs 13.
28
Before assembling, lubricate the inside of each piston
hole on the cylinder 14 with hydraulic oil.
13x9
Before assembling, lubricate with the specified hydraulic
oil the outside of the retainer 28.
14
Insert the piston assembly in hole of the return plate 10,
and fit the piston assembly 11 and the return plate 10 to
the cylinder 14. When assembling, check the matching
marks.
8 Lubricate the sliding face of the port plate 16 with

hydraulic oil.
1
Slowly and carefully place the cylinder 14 assembly on
the port plate 16.
Insert the shaft 1 into the cylinder 14.
Place the shaft 1 and the cylinder 14, rotate the shaft 1
to fit on the spline.
14
16
9 Assemble the cradle 22, and the cradle 8, and tighten

these cradles and the housing 35 with screw.
21x2
Tightening torque: 5.9 Nm (O.6 kgf m) (4.35 lbf ft).
When assembling confirm the direction of the cradle 22, 8

and the cradle 8.
22
35
9803/6030 Issue 1
24 - Hydraulic Pump 24 - 10

10 Assembling the housing assembly. 36
Before assembly, lubricate the sliding face of the cradles

22, and 8 with hydraulic oil.
35
Install the cam 36 into the housing 35. Be careful not to
damage the cradles and the cam 36. Push the cover 9 9
into the hole of the housing 35. 27
Tighten the four bolts 12 to a torque of 32.3 Nm (3.3 kgf
m) (23.82 lbf ft) using a 6mm hexagon torque wrench.
Tighten the plug 27 to a torque of 32.3 Nm (3.3kgf m)

(23.82 lbf ft) using a 6mm hexagon torque wrench.
12x4
11 Before assembly lubricate the sliding face of the piston

assembly 11 with hydraulic oil. 1
Lower the housing assembly 35 slowly with a wire rope.

35
Be careful not to damage the sliding face of the cam
and the shaft 1.
Assemble the four bolts 42 and tighten using a 14mm

hexagon wrench.
42x4
12 Assemble the inner race of taper roller bearing 7 onto

the shaft 1 using a plastic faced hammer until the
bottom face of the inner race of taper roller bearing 7
7
touches the face A of the shaft. 1
Assemble the outer race of taper roller bearing 7 into the A

housing 35.
35
9803/6030 Issue 1
Hydraulic Pump - Assembly (continued) 3
13 Seat retainer 3 into the housing.
Tighten the seal retainer 3 and the housing 35 with an

8mm hexagon socket bolts (M10 x 35, 3pcs).
Tightening torque:14.7 Nm (1.5 kgf m) (10.84 lbf ft).

35
14 Measure the clearance between the seal retainer 3 and

JIG3.
Clearance
Thickness of the shim = (2.1mm - clearance)
Dismantle the seal retainer 3. 3
Apply sealant on the outer surface of the oil seal 2 and

fit it into the seal retainer 3.
2
3
15 Before assembly, apply grease to seal lip section of the

oil seal 2 and O-ring 4. 20x6
3
Mount the shims (5 and 6) to the outer race of taper
roller bearing and push the seal retainer into the housing 4
35.
Fit the six hexagon socket bolts 20 and tighten to a 4

torque of 64.7 Nm (6.6 kgf m) (47.72 lbf ft) using an 8mm
hexagon torque wrench. 35
9803/6030 Issue 1

16 Mount the shaft of pump assembly in a downward 42x4
facing position and secure the housing with hexagon
bolts.
Tighten the four hexagon socket bolts 42 to a torque of
284Nm (29kgf m) (209.4 lbf ft) using a 14mm hexagon
torque wrench.
17 Rotate the shaft using pipe-wrench.
Confirm that the shaft 1 can rotate smoothly. If not,

dismantle and check.
Protection of the spline on the shaft is important. Protect

the surface with a soft cloth against damage.
18 Assemble the servo case assembly

79
Install the filter 56, the filter holder 55 and the plug 53 to
the servo case 79.
Tighten the plug to a torque of 19.6 Nm (2 kgf m) (14.45
lbf ft) using a 5mm hexagon torque wrench.
56 55 53
9803/6030 Issue 1
19 Install the bush 76, and power piston assembly 59.

Fasten the plate 60, the receiver 61 and the snap-ring 79
74 to the servo case 79.
76
59
74
60
61
20 Install the rod assembly 75. Fasten the piston 48, the 48
shims 50, the shims 81, the spring 78 and the spring 77
to the servo case 79. 50
78
81
77
75
79
21 Install the piston 47 to the servo cover 46. Be careful to

confirm the correct direction of the piston 47.
45x3 49
Before assembly, hold the servo case assembly 79 in a
vice. Be careful not to drop the power piston 59 etc.
Assemble the servo cover and the four hexagon socket 46

bolts and tighten the bolts to a torque of 32.3 Nm
(3.3kgf m) (28.82 lbf ft) using a 6mm hexagon torque
wrench. 47
79
9803/6030 Issue 1
Hydraulic Pump - Assembly (continued) 73
22 Assembling the return cover assembly

72
Before assembly, hold the return cover 68 in a vice.
Fit the plug assembly 67 to the return cover 68 and

tighten the plug to a torque of 216 Nm (22 kgf m) (159.3 70
lbf ft) using a 36mm hexagon torque wrench.
Install the spring 70 on the piston 72 and the rod 73 to

the return cover 68.
68
67
23 Assembling the servo case assembly to the housing 35.

52x4
35
Align matching marks on the housing and the servo
case made before dismantling.
Assemble the bolts 52 and tighten to a torque of 64.7

Nm. (6 .6 kgf m) (47.7 lbf ft) using an 8mm hexagon
torque wrench.
24 Before assembly lightly strike the lever 29 with a plastic

faced hammer until the lever 29 touches the receiver 61.
This precaution will assist in assembling the return cover 35
assembly.
Assemble the return cover assembly to the housing 35.
Align matching marks on the housing and the return
cover.
Assemble the bolts 52 and tighten to a torque of 64.7

Nm (6.6 kgf) (47.7 lbf ft) using an 8mm hexagon torque 52x4
wrench.
9803/6030 Issue 1

25 Check the assembly.
Finally, rotate the shaft 1 using pipe-wrench. Confirm

that the shaft can rotate smoothly. 1
If it cannot be rotated, dismantle and check again.
The spline of the shaft is important, protect the surface

with a soft cloth against damage.
This completes assembly.
9803/6030 Issue 1
25 - 1 Valve Location 25 - 1
Machine Valve Location
10
7 2
4 1 Control Valve
2 Pilot Supply Valve
6
3 Remote Control Valve - Left
5
4 Shuttle Block
5 Swing Offset Solenoid
6 Travel Left
7 Travel Right
8 Grab Rotate
9 Dozer Valve
10 Remote Control Valve - Right
9803/6030 Issue 1
26 - 1 Remote Control Valve (Services) 26 - 1
Introduction
This section deals with the Remote Control Valve which provides pilot pressure for the hydraulic control valve and electrical
switching to flow-control solenoids.
The remote control valve is a pressure reduction valve used to control the pilot pressure operated system. Four pressure
reduction valves used to control the pilot pressure are located in the main housing. Direction of the output pilot pressure is
controlled by selective movement of the control lever. The valves and control levers are mounted in the arm rests on both sides
of the operator’s seat.
Specification
Control operation angles Single handle ± 19°
Weight Single handle 2.8 kg
9803/6030 Issue 1
E A T P
F GB C
H D
JS06780 1 2 3 4
JS03240
27
Key
22
29
RH Control
A Spare
8
B Aux. circuit
(i.e. Grab Rotate (anti-clockwise))
C Aux. circuit 33 13
(i.e. Grab Rotate (clockwise)) 10
D One touch Idle
LH Control
E Boom Offset 14
F Hammer/Aux. Select
1
G Hammer/Aux. De-select
11/12
H Horn 30/31/32
28
4
26
15/16
6
20/21
25 2
18/19
24 3
17
7
5
23
9
A357400
Item Description Qty. Item Description Qty. Item Description Qty.

1 Casing 1 12 Push rod (ports 2 & 4) 2 23 Circular plate 1
2 Port plate 1 13 Seal 4 24 Adjusting nut 1
3 Seal washer 2 14 ‘O’-ring 4 25 Lock nut 1
4 ‘O’-ring 1 15 Spring seat (ports 1 & 3) 2 26 Lever 1
5 Screw 2 16 Spring seat (ports 2 & 4) 2 27 Control handle 1
6 Spring pin 1 17 Washer 4 28 Spring Pin 1
7 Bush 1 18 Spring (ports 1) 1 29 Grommet 1
8 Plate 1 19 Spring (ports 2,3 & 4) 1 30 Connector pin 8
9 Spool 4 20 Spring (ports 1 & 3) 2 31 Connector Housing 1
10 Guide 4 21 Spring (ports 2 & 4) 2 32 Connector Housing 2
11 Push rod (ports 1 & 3) 2 22 Joint 1 33 Gaiter 1
9803/6030 Issue 1
Operation
The assembly of the pilot pressure control valve is shown on

facing page.
The pressure reduction unit is comprised of spools 9,

pressure control springs 20/21, return springs 18/19 and
spring seats 15/16. The spools 9 are held against the push
rods 11/12 by the return springs 18/19. When the control
handle is tilted, the push rods 11/12 move down, depressing
the return spring seats 15/16, simultaneously compressing
the pressure control springs 20/21, moving the spool,
allowing hydraulic oil to flow to the designated pilot port.
The lower end of the main body 2 contains the main inlet port
P, outlet port T to tank and the pilot pressure outlet ports 1,
2, 3 and 4.
The pilot pressure controls the stroke and direction of the

main control valve spools. This is achieved by providing a
spring at one end of the main control valve spools and
applying pilot pressure to the opposite end. (In some cases,
pilot pressure is applied to both ends of the control valve
spool.)
Function
Oil supplied by the hydraulic pilot pump enters at port P and

the function of the spools 9 is to direct oil from the inlet port P
to the output ports 1, 2, 3 and 4 or alternatively, to the
exhaust port T to tank. The pressure control springs 20/21
act on the spools 9 to determine pressure at each port. Push
rods 11/12 slide in the guides 10 to vary the compression in
the springs 20/21. The control handle, fixed to the adjusting
nut 24 and circular plate 23 is operated to move the push
rods 11/12. The control handle is able to rotate 360° around
the joint 22.
The return springs 18/19 operate between the casing 1 and

the seats 10, regardless of the outlet pilot pressure, returning
the push rods 11/12 to their outer positions, ensuring the
spools 9 return to their neutral (closed) positions. The springs
18/19 also provide a resistive force, giving the operator a
‘tactile feel’ of the controls.
The control handles contain electrical push button and rocker

switches which are used to operate auxiliary services (see
facing page).
9803/6030 Issue 1
Dismantling and Assembly

Notes:
1 All parts are precision made and require the utmost care
when being handled.
2 During dismantling, do not use excessive force to

separate components which could cause scratches or
burrs on bearing surfaces. Failure to observe this
instruction will cause oil leaks leading to poor
performance.
3 Label all parts during dismantling, to ensure correct

assembly.
4 Storing the valve when dismantled could cause rusting

of parts. Ensure they are suitably protected by anti-rust
treatment.
5 During assembly, ensure all parts are clean and free

from burrs and scratches. Remove minor damage by
lapping.
6 Renew all ‘O’-rings, seals and back-up rings. Take care

to install seals the correct way around.
7 During assembly apply hydraulic oil to ‘O’-rings and

seals.
8 Ensure all screws and bolts are tightened to the torque

settings given.
Dismantling
Note: For part number identification for the main valve

assembly, see illustration in Remote Control Valve
(Services).
1 Push down upper section of gaiter 33 and remove

spring pin 28.
2 Remove control handle from lever 26.
Note: Take care when removing handle to avoid damage to

wiring loom and switches. These should be removed by
separating the line connectors in the control handle and
below the valve body.
3 Remove gaiter 33 from valve housing.
4 Slacken locknut 25 and remove lever 26.
5 Slacken and remove adjusting nut 24 and circular plate

23.
6 Using a jig, slacken and unscrew joint 22, releasing

retaining plate 8.
Note: Ensure retaining plate moves freely to prevent sudden

release due to spring pressure beneath.
9803/6030 Issue 1
Dismantling and Assembly (cont’d)
Dismantling (cont’d)
7 Remove mounting screws (4 off) and lift out control

valve.
8 Clean the valve exterior using approved solvent and

using soft metal pads for protection, clamp the valve
body into a vice.
9 If the return springs 18/19 are weak, the sliding

resistance of the seal 14 will cause the guides 10 to
stick in the casing. Using a screw driver, carefully ease
out the guides 10 and push rods 11/12.
Note: Care must be taken to prevent damage to the guides

when removing. Ensure the guides do not fly out due to the
force of the return springs.
10 Remove spring seats 15/16, return springs 18/19,

pressure control springs 20/21 and spools 9.
Note: Identify each set of parts and their locations for

assembly.
11 Slacken and remove body assembly screws 5. Remove

and discard ‘O’-ring 3.
12 Separate upper and lower body sections 1 and 2 and

remove spring pin 6.
13 Remove and discard ‘O’-ring 4.
14 Hold spools 9 firmly on the work bench and depress

spring seat 15/16.
Note: Avoid scratching the surface of the spools. Do not

depress the spring seats more than 6 mm (0.24 in).
15 Separate spools 9, spring seats 15/16, springs 20/21

and 18/19 and washer 17.
16 Remove push rods 11/12 from guides 10.
17 Remove seals 13 and 14 from guide 10 and discard.
Note: Leave all parts to soak in suitable solvent until dirt is

loosened. Using clean solvent wash all parts and allow to air
dry. Apply rust inhibitor to all parts.
9803/6030 Issue 1
Dismantling and Assembly (cont’d)
Assembly
The numerical sequence given previously is a guide to

dismantling. For assembly the sequence should be reversed
noting the following details:
1 Locate plate 8 onto guides 10 Screw joint 22 into

position. Torque tighten to 47 Nm (4.7 kgf m, 35 lbf ft).
2 Locate circular plate 23 and torque tighten to 68 Nm

(6.9 kgf m, 57 lbf ft), until it makes contact with the push
rods 11/12. Ensure the push rods are not depressed at
this stage.
3 Holding the circular plate 23 in its position, screw down

adjusting nut 24. Torque tighten to 68 Nm (6.9 kgf m, 57
lbf ft). Screw down lock nut 25. Torque tighten to 49 Nm
(36 kgf m, 4.9 lbf ft).
4 When fitting the body assembly screw 5 and seal

washer 3 torque tighten to 20 Nm (2.0 kgf m, 14.7 lbf ft).
5 Ensure the switch cable is free from obstruction and the

line connectors are securely fastened.
9803/6030 Issue 1
Maintenance Specification
Maintenance Item Standard Note
Leakage Amount Replace if the leakage exceeds 1.0 Condition:

litre/min (0.22 gal/min) with the handle in Primary pressure 29 bar
the neutral position or 2.0 litre/min (0.44 (30 kgf/cm2 426.5 lbf/in2).
gal/min) during operation. Oil viscosity 23 cSt.
Spool Replace when the sliding contact faces are The conditions are approximately
worn more than 0.01 mm (0.0004 in) or the same as for the leakage
more than the non-sliding contact faces. above.
Push rods 11/12 Replace if the

tip is worn
more than 1
mm (0.039 in).
JS02060
Loose movement in the operating Replace the parts if the wear in the pin and
controls. joint lead to loose movement of more than
2 mm (0.079 in).
Investigate if abnormal noises, jerky

Actuation stability. operation or drops in primary pressure are
experienced during operation. Replace the
valve if the problem cannot be solved.
Note: Ensure that ‘O’-rings and other seals are renewed during reassembly. If the screw 5 is loosened, always replace the Seal
washer 3.
9803/6030 Issue 1
30 - 1 Control Valve 30 - 1
Control Valve
1 SWING
2 TRAVEL LH
3 TRAVEL RH
4 BUCKET
5 BOOM
6 DOZER
7 ARM
8 OFFSET
9 HAMMER/AUXILIARY
MRV MAIN RELIF VALVE Ps2
P
Pc1
Pc2
Ps2
PN
a9 A9 B9
8
a8 A8 B8
7
a7 A7 B7
6
a6 A6 B6 5
a5 A5 B5 4
a4 A4 B4 3
a3 A3 B3 2
a2 A2 B2 1
a1 A1 B1
MRV
a1 a1 PN P A353990
9803/6030 Issue 1
Precautions During Use Dismantling and Assembly

Installation Dismantling
Ensure that excessive force is not put on the valve by the

piping.
! WARNING
Hydraulic Pressure
Tighten the installation bolts to the specified torque. Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses or
Take care when welding work is done near the valve, couplings, vent the pressure trapped in the hoses in
excessive heat can damage the seals. accordance with the instructions given in this publication.
HYD 1-5
To prevent foreign matter from entering the ports, do not

remove the plugs from the ports until installation. Before working on the hydraulic system, ensure that the
engine is switched off and the starter key removed.
Running
Disconnect all hydraulic hoses from valve ports. Seal
Operate only after confirming that the hydraulic circuit and exposed connections to prevent the ingress of dirt. Mark the
hydraulic oil are clean. hoses to ensure correct re-connection.
Use the hydraulic oil specified in this manual. Disconnect all pilot hoses from spool housing. Seal ports to
prevent ingress of dirt. Mark the hoses to ensure correct
Do not raise the pressure of the main relief valve or port relief reconnection.
valve set pressures.
Remove securing screws and lift the valve block from the
The difference between the main relief valve and port relief machine.
valve set pressures should be more than 19.6 bar (20 gf/cm2)
(285 lbf/in2).
Assembly
Carry out warming up sufficiently before beginning actual
operations. Because of the low temperature of the oil and Replacement is the reverse of the removal procedure.
valve, note the following points in particular, to prevent
seizure of the main spools due to heat shock: Ensure all hoses and ports are clean and free from dirt.
1 Do not operate the main relief valve or port relief valve

continuously on a cold machine, but operate so that the
hydraulic oil in each ram can circulate, thereby warming
up each part uniformly.
2 Fine and combined operations cause heat build-up, do

not perform sudden operations at low temperatures.
9803/6030 Issue 1
9803/6030 Issue 1
60 - 1 Pilot Supply Valve 60 - 1
Pilot Supply Valve
Main pressure from the pump (min. of 40 bar) enters port P.

Oil then passes through the 40 bar pressure reduction valve
(PRV). The oil (40 bar) is then available to all the other
solenoids in the pilot supply valve.
There is a 45 bar pressure reduction valve in line with the 40

bar PRV, known as the secondary relief valve. If the 40 bar
PRV fails for any reason, then the 45 bar PRV will stop full
pump pressure up to (300 bar) from entering or damaging
any other service.
Solenoids A and B - see Swing Brake/Lock Operation.
Solenoid C - is the High Speed Tracking Solenoid - When

the servo isolator solenoid is energised, 40 bar pressure is
available from the solenoid to the pilot manifold via the servo
filter.
Solenoid D - is the servo isolator solenoid - see Swing

Brake/Lock operation.
9803/6030 Issue 1
Dismantling and Assembly
All the cartridges are renewable and are supplied with all
relevant seals and ‘O’ rings. Replacement seal kits may be
obtained if required. When assembling, care should be taken
not to overtighten the cartridges, due to the possibility of
stripping the threads in the valve block (see Torque
Settings).
Torque Settings
Item Torque
Nm kgf m lbf ft
CT1 60 6.1 44
CT2 4 4.6 33
CT3/4/6/9 30 3.0 22
CT3/4/6/9A 3.5 0.35 2.6
CT5 45 4.6 33
CT7 60 6.1 44
CT8 10 1.0 7.4
A358590
9803/6030 Issue 1
Pilot Line System
1 Swing
1 2 Travel LH
b1
a1
3 Travel RH
4 Bucket
2
b2
a2
5 Boom
6 Dozer
3
b3
a3
7 Arm
8 Offset
4
b4
a4
9 Hammer/Auxiliary
10 Joystick RH
5
b5
a5
11 Joystick LH
O
10
10
V
12 Cab Manifold
6
b6
a6
Y/G
LB
10
10
13 Shuttle Block
14 Travel Pedal
GR
10
10
B
7
b7
a7
11
11
Y
G
BL
11
11
R
8
b8
a8
L/G
P
8
8
9
b9
a9
1
2
3
4
1
2
3
4
T1
T6
CL
CL
T
T
11
0 !
P1
P6
W
W
P
P
11
8
T5 P5
@
CL
O
9
8
A6
A5
A4
A3
A2
A1
V
9
£
B6
B5
B4
B3
B2
B1
GR
Y/G
LB
B
9
9
2
$
1
1
P
9803/6030 Issue 1
71 - 1 Hydraulic Rams 71 - 1
Precautions During Use

1 Precautions when installing the ram on the machine
! CAUTION
When installing and removing rams on the machine, suspend the ram safely.
Suspending the ram by the piping is not only dangerous, but can also cause damage to the cylinder.
Secure the piston rod with a band. It is very dangerous if the rod extends unexpectedly. Also, the rod can be damaged
and become unusable.
Welding after installing the ram may result in damage.

If electric welding is done even at a point away from the ram, there may be sparking inside the ram and it will become
necessary to replace the ram with a new one.
When painting the machine, mask the ram.

If paint adheres to the rod surface or to the wiper ring and the ram is operated, the wiper ring will not function properly
and foreign matter and paint can easily enter the ram. This will cause damage to the seals, drastically shortening the life
of the ram.
Install the ram only when it is clean.
2 Caution During Use

! CAUTION
Use only under designated conditions.
If hydraulic oil other than the designated oil is used, the seals quickly degenerate and become damaged. If the relief valve
is set at a value higher than specified, it may cause ram damage and is dangerous.
In high temperature environments (approx. 90°C and above) or low temperature environments (below -20°C), seals
quickly become damaged. Special seal materials are necessary so check to see if the ram that you are using is suitable or
not.
The number one cause of ram oil leakage is rod damage. Be careful not to damage the rod.
Warm up sufficiently before beginning work.

In cold conditions the rod seals may be frozen, so if the ram is operated at maximum pressure and maximum speed, the
seals will be damaged.
There is a large amount of air in a new ram or one which has been left for a long time, so the ram will not operate
smoothly. Also, if pressure is applied suddenly without bleeding the air, high temperatures will be generated due to
adiabatic compression and the seals may burn.
Before beginning work, always move the ram at full stroke with no load and expel air from the cylinder.
When stopping or storing, do it at a safe and fixed position.

The installed ram cannot maintain the same position for a long period of time, because the oil inside the ram may leak
and the hydraulic oil volume decreases as it cools. Stop or store the machine in a safe and fixed position.
3 Maintenance, Inspection Points.
Carry out daily maintenance and inspection.

The key point for correct long-term ram function is daily maintenance and inspection. Carry out maintenance and
inspection so that the ram functions fully at all times. Always remove any mud, water, dust or oil film adhering to the rod
and keep it in normal condition. However, when cleaning the wiper ring and seals, do not get them wet with water but
wipe clean with a rag. If leaving for more than one week, apply anti-rust oil to the rod surface.
Use genuine JCB parts when replacing parts.

If parts other than genuine JCB parts are used, the desired results may not be obtained. Use only genuine JCB parts.
Caution during dismantling and reassembly.

Dismantling the ram while it is still installed on the machine can be dangerous as unexpected movements of the machine
can occur. Remove the ram from the machine and then dismantle.
If reassembled with dirty hands, foreign matter can enter the ram causing a shorter life span and also the other hydraulic
equipment may be damaged. Reassemble in a clean state.
Follow the instructions in the diagrams regarding torque tightening for screwed parts. If the torque is too high or too low,
it can cause damage.
9803/6030 Issue 1
Bucket Ram - Removal
! WARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the
engine and operate the controls to release pressure
trapped in the hoses. Make sure the engine cannot be
started while the hoses are open.
INT-3-1-11/1
! WARNING
Lifting Equipment
You can be injured if you use faulty lifting equipment.
Make sure that lifting equipment is in good condition.
Make sure that lifting tackle complies with all local
regulations and is suitable for the job. Make sure that
lifting equipment is strong enough for the job.
INT-1-3-7
1 Lower the attachment to the ground, as shown.
A353220
2 Place a wooden block under the bucket ram.
3 Stop the engine, remove the key.
Release the tank pressure, see Releasing the Tank

Pressure in Section 3.
A343420
9803/6030 Issue 1
Bucket Ram - Removal (cont’d)
4 Remove the nuts and bolts from the rod end of the ram.
5 Push the pin out using a bar and hammer.
! WARNING
Metal Splinters
You can be injured by flying metal splinters when driving
metal pins in or out. Use a soft faced hammer or drift to
remove and fit metal pins. Always wear safety glasses.
INT-3-1-3
6 Restrain the eye end of the ram piston rod to the ram
cylinder to prevent the piston rod from extending.
7 Remove the ram hoses and install plugs or caps to

prevent contamination.
9803/6030 Issue 1
Bucket Ram - Removal (cont’d)
8 Attach a sling to support the ram.
9 Remove the nuts and bolts from the cylinder end of the
ram. Push out the pin using a bar and hammer. Lift the
ram clear.
! WARNING
Metal Splinters
INT-3-1-3
Bucket Ram - Replacement
1 Attach a sling to the ram and lift it into position on the

dipper.
2 Install the pin, bolt and nuts to the cylinder end of the
ram.
9803/6030 Issue 1
Bucket Ram - Replacement (cont’d)
3 Connect the hoses.
4 Hoist the ram to align with the link.
5 Install the pin, bolt and nuts.
Note: Stroke the ram to release entrapped air. After

releasing the air, check for oil leakage.
9803/6030 Issue 1
Arm Ram - Removal

! WARNING
Hydraulic Pressure
INT-3-1-11/1
! WARNING
Lifting Equipment
INT-1-3-7
1 Lower the attachment to the ground, as shown.
A353220
2 Place a wooden block under the arm ram.
3 Stop the engine, remove the key.

Release the tank pressure (see Releasing the Tank
Pressure - Section 3).
A343420
9803/6030 Issue 1
Arm Ram - Removal (cont’d)
4 Remove the nuts and bolts from the rod end of the ram.
5 Push out the pin, using a bar and hammer.
! WARNING
Metal Splinters
INT-3-1-3
6 Restrain the eye end of the ram piston rod to the ram
cylinder to prevent the piston rod from extending.
7 Remove the ram hoses, and install plugs or caps to

prevent contamination.
9803/6030 Issue 1
Arm Ram - Removal (cont’d)
8 Remove the grease tube.
9 Attach a sling to support the ram.
10 Remove the nuts and bolts from the cylinder end of the
ram, push out the pin using a bar and hammer. Lift the
ram clear.
! WARNING
Metal Splinters
INT-3-1-3
Arm Ram - Replacement
1 Attach a sling and lift the ram onto the boom.
9803/6030 Issue 1
Arm Ram - Replacement (cont’d)
2 Install the pin, bolts and nuts.
! WARNING
Metal Splinters
INT-3-1-3
3 Install the grease tube.
4 Connect the hoses.
5 Hoist the ram to align the piston rod eye end with the
dipper pin position.
9803/6030 Issue 1
Arm Ram - Replacement (cont’d)
6 Install the pin, bolt and nuts.
Note: Stroke the ram to release entrapped air. After releasing

the air, check for oil leakage.
! WARNING
Metal Splinters
INT-3-1-3
9803/6030 Issue 1
Boom Ram - Removal

! WARNING
Hydraulic Pressure
INT-3-1-11/1
! WARNING
Lifting Equipment
INT-1-3-7
1 Park the machine on level ground and, with the dipper

and bucket rams fully retracted, lower the bucket to the
ground.
A353220
2 Using a hoist capable of supporting the ram weight of

84 Kg. (185 lb), attach a sling to the ram.
284440
3 Remove the nuts and bolt securing the boom pivot pin.
Knock out the pivot pin using a bar and hammer.
! WARNING
Metal Splinters
INT-3-1-3
284450
9803/6030 Issue 1
Boom Ram - Removal (cont’d)
4 Lower the boom ram and support it on a stand.
284460
5 Fasten a wire to hold the piston rod inside the cylinder.
284470
6 With the engine stopped, the starter switch set to ON

and the operation control switch set to ON, operate the
hydraulic controls to relieve system pressure. Release
hydraulic tank pressure as described in Section 3.
7 Disconnect the two boom ram hoses.
Install plugs and caps to prevent contamination.
284480
9803/6030 Issue 1
8 Remove the nuts and bolt securing the body pivot pin.
284490
9 Knock out the pivot pin with a bar and hammer.
! WARNING
Metal Splinters
INT-3-1-3
284500
10 Lift the boom ram away from the body.
284510
Boom Ram - Replacement

1 Use a suitable hoist and sling (the ram weighs 84 kg
(185 lb)), to position the ram over the body pivot pin.
284520
9803/6030 Issue 1
Boom Ram - Replacement (cont’d)
2 Install the body pivot pin. Secure with the bolt and nuts.
284530
3 Connect the hoses to the boom ram.
284540
4 Raise the boom ram and align the boom piston rod eye
with the boom pivot point.
284550
5 Install the pin with a bar and hammer. Secure with the
bolt and nuts.
! WARNING
Metal Splinters
INT-3-1-3
286980
9803/6030 Issue 1
Offset Boom Ram - Removal

! WARNING
Hydraulic Pressure
INT-3-1-11/1
! WARNING
Lifting Equipment
INT-1-3-7
1 Park the machine on level ground and, with the dipper

and bucket ram fully retracted, lower the bucket to the
ground.

42 kg (92 lb), attach a sling to the offset ram.
With the engine stopped, the starter switch set to ON

hydraulic tank pressure as described in Section 3.
284570
3 Remove the nuts and bolt securing the offset boom

pivot pin. Extract the pivot pin.
! WARNING
Metal Splinters
INT-3-1-3
284580
9803/6030 Issue 1
Offset Boom Ram - Removal (cont’d)
4 Use a wire to hold the piston rod inside the cylinder.
284970
5 Disconnect the two offset ram hoses.
Install plugs or caps to prevent contamination.
286990
6 Remove the nuts and bolt securing the main boom

pivot pin. Take out the pivot pin.
284800
7 Lift the offset ram clear.
284810
9803/6030 Issue 1
Offset Boom Ram - Replacement (cont’d)
1 Use a suitable hoist and sling (the ram weighs 42 kg (92

lb)), to align the offset ram cylinder ram eye with the
main boom pivot point.
284820
2 Install the pivot pin and secure with the bolt and nuts.
! WARNING
Metal Splinters
INT-3-1-3
284830
3 Connect the hoses to the offset ram.
284840
4 Align the piston rod eye with the offset boom pivot
point.
284850
9803/6030 Issue 1
Offset Boom Ram - Replacement (cont’d)
! WARNING
Metal Splinters
INT-3-1-3
284860
9803/6030 Issue 1
Blade Ram - Removal

! WARNING
Hydraulic Pressure
INT-3-1-11/1
! WARNING
Lifting Equipment
INT-1-3-7
1 Lower the bucket and the blade to the ground.
A351150
2 Put a wooden block under the blade ram.
With the engine stopped, the starter switch set to ON

hydraulic tank pressure as described in Section 3
284880
3 Remove the nuts and bolt securing the blade ram pivot
pin to the body.
Knock out the pivot pin using a bar and hammer.
! WARNING
Metal Splinters
INT-3-1-3
284890
9803/6030 Issue 1
Blade Ram - Removal (cont’d)
4 Use a wire to hold the piston rod inside the cylinder.
284900
5 Disconnect the blade ram hoses. Install plugs or caps

to prevent contamination.
284910

42 kg (92 lb), attach a sling to the ram.
284920
7 Remove the nuts and bolt securing the blade pivot pin.
Knock out the pivot pin.
! WARNING
Metal Splinters
INT-3-1-3
284930
9803/6030 Issue 1
8 Lift the blade ram clear.
284940
Blade Ram - Replacement

1 Use a suitable hoist and sling (the ram weighs 42 kg (92
lb)) to align the ram cylinder eye with the blade pivot
point.
284950
284960
9803/6030 Issue 1
Blade Rams - Replacement (cont’d)
3 Connect the hoses to the blade ram.
284980
4 Manoeuvre the blade ram to align the cylinder rod eye

with the body pivot point.
284990
! WARNING
Metal Splinters
INT-3-1-3
284550
9803/6030 Issue 1
Ram Piston Head Nut - Removal and Fitting
JS00980
9803/6030 Issue 1
Ram Piston Head Nut (cont’d)
Due to the high piston nut tightening torques used on the Nut Fitting
rams, it is necessary to use a special rig (consisting of the
special tools shown in the Tables) for ram piston head nut Before assembly ensure that all components have been
fitting and removal (see Section 1 - Service Tools). thoroughly cleaned and all new seals, backing rings and ‘O’-
rings are available. Smear all seals, etc. with hydraulic fluid.
As shown in illustrations A and B, the rig uses a modified lift
ram C acting on a heavy-duty ring spanner D to loosen or 1 Assemble the piston rod components as detailed earlier
tighten the piston nut. Hydraulic power to operate the rig for individual rams.
may be obtained from a suitable hydraulic power pack
(maximum pressure required 150 bar (2175 lb/in2) or from 2 Install the piston rod assembly in the nut removal/fitting
the auxiliary circuit of a JCB machine equipped with quick- rig with the piston rod supported by block J.
release couplings. In either case, small bore hoses E (Part
No. 892/00137 - 2 off) must be used to connect the rig to 3 Secure the eye end of the piston rod to the rig at
the power source to limit the speed of operation of ram C. In position G, using a suitable pivot pin.
addition F, test point (Part No. 892/00262) and pressure
gauge (Part No. 892/00279) should be fitted in the line to the 4 Fit a ring spanner to the piston nut and connect it to the
piston side of the ram C to measure the tightening pressure eye end of ram C at position K.
being applied.
5 Using the rig, tighten the piston head nut H to the
See Table 1 on the following page for details of the pressure torque specified for individual rams by powering the
necessary to achieve the required tightening torques. The ram slowly downwards. The torque required is indicated
torque settings themselves are given on Table 2 of the same by gauge F (see Table 1 on following page).
page.
6 Remove the piston rod assembly from the rig and insert
Nut Removal into the ram cylinder.
It is assumed that the ram has been removed from the

machine, hydraulic piping removed and the piston rod
assembly separated from the cylinder.
Note: Before using the nut removal/fitting rig, operate the rig
cylinder over its full range for 5 or 6 strokes to remove all air
from the cylinder.
1 Install the piston rod assembly in the

dismantling/assembly rig with the piston rod supported
by block J.
2 Secure the eye end of the piston rod to the rig at

position G, using a suitable pivot pin.
3 Fit a ring spanner to the piston nut and connect it to the

eye end of ram C at position H.
4 Power the ram slowly downwards, noting the pressure

at which the piston nut first moves on the piston rod.
(The pressure should be 1.0 to 1.5 times the tightening
pressure for the particular size).
5 Remove the piston nut.
6 Remove the piston rod assembly from the rig and then
proceed with dismantling.
9803/6030 Issue 1
Ram Piston Head Nut (cont’d)

Nut Fitting (cont’d)
Table 1
Required Tightening Necessary Gauge

Torques Pressure
Nm lbf ft bar lbf/in2
640 472 4.4 64
1400 1033 9.6 140
1470 1084 10.1 147
1790 1320 12.3 179
1840 1357 12.7 184
1900 1401 13.1 190
2230 1645 15.4 223
2300 1696 15.9 230
2620 1933 18.1 262
3480 2567 24.0 348
3580 2641 24.7 358
3590 2648 24.7 359
4590 3385 31.6 459
4820 3555 33.2 482
5140 3791 35.4 514
6220 4588 42.8 622
8700 6417 60.0 870
9100 6712 62.7 910
9330 6882 64.3 933
9425 6952 64.9 942
10700 7892 73.8 1070
10740 7922 74.0 1074
12700 9367 87.6 1270
12750 9404 87.9 1275
14000 10326 96.5 1400
16900 12465 116.5 1690
17700 13055 122.0 1770
19615 14468 135.2 1961
21000 15490 144.8 2100
21500 15858 148.3 2150
The torque is determined by reading the pressure on gauge

F in the rig circuit (with the spanner at 90° to the rig ram) and
converting it according to the table above.
Note: The pressures in the above table assume that the rig
is used with spanners having 500 mm centres.
9803/6030 Issue 1
77-4 Torque Specifications 77 - 4
Bucket Ram
Nm kgf m lbf ft Remarks
End Cap 490 ± 110 49.98 ± 11.2 361.4 ± 81.13 M90 x 2
Grub Screw 16.2 ± 3.04 1.65 ± 0.31 11.9 ± 2.24 M8 x 1.25
Piston Nut 1520 155 1121 M39x2
Boom Ram
End Cap 647 ± 148 66 ± 15 477 ± 109 M105 x 2
Grub Screw 31.5 ± 5.88 3.2 ± 0.6 23.2 ± 4.3 M10 x 1.5
Piston Nut 1980 202 1460.39 M45 x 2
Arm Ram
End Cap 569±129 58 ± 15 420 ± 95 M100 x 2
Grub Screw 31.5 ± 5.88 3.2 ± 0.6 23.2 ± 4.3 M10 x 1.5
Piston Nut 1900 194 1401 M42 x 2
Offset Boom Ram

End Cap 647 ± 148 66 ± 15 477 ± 109 M105 x 2
Grub Screw 31.5 ± 5.88 3.2 ± 0.6 23.2 ± 4.3 M10 x 1.5
Piston Nut 1400 143 1033 M45 x 2
Blade Ram
End Cap 382 ± 87 39 ± 8.9 281 ± 64 M75 x 2
Grub Screw 16.2 ± 3.04 1.65 ± 0.31 11.9 ± 2.24 M8 x 1.25
Piston Nut 637 65 470 M33 x 2
9803/6030 Issue 1
80 - 1 Rotary Coupling 80 - 1
F
J
A
F
D
C
H
J
H2070
9803/6030 Issue 1
Description
The rotary coupling distributes hydraulic fluid under pressure,
through transfer ports in the fixed inner core, to their
associated port of the rotating outer shell.
The outer shell A is machined from a type Fe 52 steel
forging,which is phosphated after machining. The outer shell
has eight hydraulic fluid ports B arranged in two groups of
four. All galleries on the inner surface of the outer shell are
sealed to the inner core with O-ring seals and back-up rings
C. In addition, the inner surface of the outer shell is fitted with
top and bottom lip seals D which seal to the top and bottom
of the inner core. The outer shell has four fixing lugs E welded
to its outer surface which are used for mounting the coupling
to the machine undercarriage.
The inner core F is a machined carbon steel component, with
a hard chromed working surface, in which are machined the
eight hydraulic fluid transfer ports. The core is fitted with an
external top seal J and is retained within the outer shell with a
hardened steel bottom retaining plate H, also sealed, which is
bolted to the bottom of the core. A reaction peg K is welded
to the top of the inner core, which locates in a slotted plate in
the mainframe.
Operation
When the outer shell A of the rotary coupling rotates around
the fixed inner core, the transfer ports G of the inner core
align with the ports of the outer shell B. Hydraulic fluid under
pressure from the hydraulic pump, is then routed via a
transfer port of the inner core, to the required service.
9803/6030 Issue 1
D
N
C
L A
C
L
A357430
9803/6030 Issue 1
Removal and Replacement Dismantling and Assembly

Removal Dismantling
! WARNING 1 Mark the positions and remove the adaptors M and P

Fine jets of hydraulic oil at high pressure can penetrate from the coupling. Discard the O-rings.
the skin. Do not use your fingers to check for hydraulic 2 Remove the two M10 inner core retaining bolts K, from
oil leaks. Do not put your face close to suspected leaks. the base of the coupling and remove the bottom
Hold a piece of cardboard close to suspected leaks and retaining plate and seal.
then inspect the cardboard for signs of hydraulic oil. If
hydraulic oil penetrates your skin, get medical help 3 From the top of the coupling, carefully withdraw the
immediately. coupling core F from the shell A.
HYD001
4 Remove and discard the inner core top and bottom V
! WARNING seal D and port O-rings and back-up rings C, from the
A raised and badly supported machine can fall on you. inner surface of the outer shell.
Position the machine on a firm level surface before Assembly
raising one end. Ensure the other end is securely
chocked. Do not rely solely on the machine hydraulics or 1 Assemble in reverse order of dismantling, fitting new O-
jacks to support the machine when working under it. rings, back-up rings and V seals. Lightly lubricate with
Disconnect the battery, to prevent the engine being hydraulic fluid, the inner core and all O-rings with
started when you are beneath the machine. hydraulic fluid.
GEN001
Replacement
1 Remove the floor plate.
1 Replace in reverse order of removal.
2 Disconnect the hydraulic hoses from the rotary coupling
adaptors M, mark for correct replacement, blank off the 2 Reconnect all hydraulic hoses using new lightly
hoses and adaptors. lubricated 0-rings.
3 Remove the undercarriage cover plate. Hose Locations (port numbers stamped on joint)
4 Disconnect the remaining hydraulic hose from the rotary Dozer ram
coupling adaptors P, Blank off the hoses and adaptors. Head side to rotary joint port no.7 Rod side to rotary
5 Support the coupling from above and remove bolts, joint port no.2
washers and nuts L securing the coupling flanges to the L.H. Track Motor
undercarrige.
Port A to rotary joint port no. 3
6 Lower the coupling, allowing the reaction peg N to clear
the slot in the mainframe floor continue to lower clear of Port B to rotary joint port no. 5
the machine and remove to a clean working surface. Top drain port to rotary joint port no. 1
Pilot port to rotary joint port no.8
R.H. Track Motor

Port A to rotary joint port no. 6
Port B to rotary joint port no. 4
Top drain port to rotary joint port no.1
Pilot port to rotary joint port no.8
9803/6030 Issue 1
83 - 1
9803/6030
Section E
B port side
make-up check
A port side relief
Hydraulic Motor Components
Bottom dead
point
Note: Item numbers are referred to on the following pages.

Make-up port
Slew Motor
Hydraulics
Top dead
point
B port side relief
A port side B port

A port
make-up check
Mechanical brake
release chamber
288550
Issue 1
83 - 1
Section E
83 - 2 Slew Motor 83 - 2
Reduction Gear Components
Key
A A chamber
B B chamber
Note: Item numbers are referred to on the following pages. 288530
9803/6030 Issue 1
83 - 3 Slew Motor 83 - 3
Hydraulic Circuit
Key
D D
A Hydraulic motor (151 cm3/rev)
B Bypass/Anti-pendulum valve
C Anti-cavitation check valve
D Relief valve (285 kgf/cm2 @ 155 l/min) C C
E Mechanical brake
F
F Tank line
G Drain line
JS02680
9803/6030 Issue 1
90 - 1 Slew Motor 90 - 1
Operation
Slew Motor Configuration
Slew Unit
Planetary 2-stage Reduction Gear Swash Plate Type Axial Piston Hydraulic Motor
Mechanical Brake
By-pass Valve Relief Valve
Make-up Valve
The above diagram indicates the relationships between the main components of the slew motor, whose working principles are
described on the following pages.
9803/6030 Issue 1
91 -1 Slew Motor 91 - 1
Maintenance Specifications
Item Inspection and Maintenance Standards
The crescent-shaped ports in the balance plate, which are in sliding contact with
the end face of the cylinder assembly shaft, act to switch between high and low oil
pressure. Any damage to the sliding contact face will increase leakage, causing a
decrease in volumetric efficiency and an increase in slip.
Balance Plate 7 Any seizure of the sliding contact face causes a reduction in mechanical efficiency
and can lead to further damage.
If the grooves or marks depths are less than 0.03 mm (.001 in), the plate can be
corrected using fine emery cloth.
If the wear is greater than 0.03 mm (.001 in), the plate should be renewed. The
plate should be renewed if it shows any sign of seizure.
Correct any damage to the sliding contact face of the slipper feet by using fine
Piston assembly 18 slipper feet emery cloth.
Renew the motor if the depth of any slipper foot oil groove is less than 0.45 mm
(.018 in) or if the slipper foot surfaces are seriously damaged.
Piston assembly 18 pistons The external surfaces of the piston assemblies should be practically unworn. The
motor should be renewed if a piston assembly shows any sign of seizure.
Cylinder assembly 16 piston bores The piston bores should be practically unworn. The motor should be renewed if
the bores show any sign of seizure or are badly damaged.
HYDRAULIC MOTOR The bearings should be renewed if any slight damage is noticed on the contact
Taper roller bearing 1 surfaces of the rollers or needles.
Needle bearing 3 It is recommended that all bearings be renewed on reassembly of the motor
REDUCTION GEAR because bearings can be damaged when the motor is dismantled.
Taper roller bearing 4,8
HYDRAULIC MOTOR Renew any oil seal if damage to the lip is apparent.
New seals must be used when reassembling the motor.
REDUCTION GEAR
Oil seal 7
HYDRAULIC MOTOR Renew any 'O'-ring that appears to be damaged.

O-rings 6, 8, 25, 27, 30, 33 New 'O'-rings must be used when reassembling the motor.
HYDRAULIC MOTOR The back-up rings must be renewed when reassembling the motor.
Back-up ring 24, 32
! CAUTION ! WARNING
If the machine is operated at full load, before its initial Hydraulic Pressure
run-in procedure is complete, it may cause scuffing and Hydraulic fluid at system pressure can injure you. Before
seizing which can adversely effect the service life of the disconnecting or connecting hydraulic hoses, stop the
machine. engine and operate the controls to release pressure
8-3-1-5
! WARNING INT-3-1-11/1
Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can penetrate
the skin. Do not use your fingers to check for hydraulic
fluid leaks. Do not put your face close to suspected
leaks. Hold a piece of cardboard close to suspected
leaks and then inspect the cardboard for signs of
hydraulic fluid. If hydraulic fluid penetrates your skin, get
medical help immediately.
INT-3-1-10/1
9803/6030 Issue 1
92 - 1 Slew Motor 92 - 1

Dismantling
Refer to the sectional drawing on page E/83-1 as a guide to
dismantling and assembling.
Before attempting to dismantle the slew motor assembly, the

inlet and outlet ports should be blanked and the outer
surfaces washed down with a suitable solvent to remove all
dirt and dust. Dry using compressed air.
1 Remove the relief assembly 23 using a 27 mm A/F 31

hexagonal key and the by-pass valve assembly 31 with
a 8mm hex, socket.
23 288620
2 Before removing the motor from the reduction gear, it is

advisable to make an alignment mark on the mating
faces to facilitate reassembly. 28
21
288630
3 Loosen the bolts 34 with a 10 mm socket wrench, place

the motor with the output shaft downwards and remove 34
the cover 28.
28
21
288640
9803/6030 Issue 1
92 - 2 Slew Motor 92 - 2

2
Dismantling (cont’d)
3
4 Remove the snap ring 2 and remove the inner ring of
the needle bearing 3 and balance plate 7.
7
The inner ring of the needle bearing 3 is pressed into
the male axis of the cover 28 and must be removed
with a gear puller.
28
Note: Record the relative positions of the parts to ensure

correct reassembly. 288650
5 Remove the O-ring 8.
28
288660
6 Remove the bushings 11 with teflon rings 13 and the

plate springs 12. 11
13
12
28
288690
7 Remove the springs 14 from the brake piston 15

Note: Keep the springs in the order in which they are to
be reinserted.
14
21
288700
9803/6030 Issue 1
92 - 3 Slew Motor 92 - 3

Dismantling (cont’d) 15
A
8 It may be difficult to remove brake piston 15 from
housing 21 due to resistance caused by ‘O’-rings 6 and
30. Remove brake piston 15 using the tapped M6 holes
with a wrench A and a support block B as shown in the B
illustration.
21
288710
9 Remove the friction plate 4 and the mating plate 5.
21
288670
10 Hold the end of the cylinder 16 by hand and pull out the
cylinder assembly from the housing 21. C
16
The outer ring of the taper roller bearing 1 remains in
the housing.
The end face C of the cylinder 16 is a sliding face and

should be protected with a clean cloth to prevent it
being damaged.
Make alignment marks or write numbers on the piston

bores of the cylinder 16 and the piston assemblies 18
so that the piston assemblies can be replaced in the
same bores during reassembly.
21
288680
9803/6030 Issue 1
92 - 4 Slew Motor 92 - 4

D
12 Remove the outer rings D of the taper roller bearing 1
from the housing 21.
21
288740
13 Attach a puller to the inner ring E of taper roller bearing

1 at two places and on the end of cylinder spline 16,
then extract bearing inner ring 22.
22
16 288750
14 Remove the cam plate 20, return plate 19 and piston

assemblies 18 from the cylinder. 20
19
18
16
288760
15 Slide cam plate 20 from the sliding faces of the piston

assemblies.
20
Note: Take care not to damage the cam plate during
handling.
19
18
288720
9803/6030 Issue 1
92 - 5 Slew Motor 92 - 5

16 Remove the spring 17 from the cylinder 16.
16
288730
Motor Assembly/Cylinder Assembly ! CAUTION

Assembly Cleaning
Cleaning metal parts with incorrect solvents can cause
Refer to the sectional drawing on page 83 - 1 as a guide to corrosion. Use only recommended cleaning agents and
dismantling and assembling. solvents.
INT-3-2-11
Check all parts before assembly and remove any scratches ! CAUTION
with a fine oil stone or carborundum paper. Wash with a ‘O’-rings, Seals and Gaskets
suitable solvent and blow dry. Badly fitted, damaged or rotted ‘O’-rings, seals and gaskets
can cause leakages and possible accidents. Renew
Replace all seals with new ones. whenever disturbed unless otherwise instructed. Do not
use Trichloroethane or paint thinners near ‘O’-rings and
Apply clean hydraulic oil to all sliding faces during assembly seals.
INT-3-2-12
1 Lap the sliding contact faces of piston assemblies 18, 18

balance plate 20 and swash plate 7 with very fine paste
on a flat surface.
288920
9803/6030 Issue 1
92 - 6 Slew Motor 92 - 6

Assembly (cont’d)
17
2 Apply grease to the curved part of cylinder 16 (contact
face with spring 17) and mount spring 17.
16
288930
3 Position the piston assemblies 18 into the holes of

retainer 19.
18
19
288940
4 Mount the piston assemblies 18 together with return plate

19 into cylinder 16.
Note: Insert the piston assemblies into the same bores from 19 18
which they were removed.
Apply clean hydraulic oil to all cylinder 16 bores before
reassembling.
17
16
288950
5 Apply clean hydraulic oil to piston assembly 18 shoe

sliding surface and mount the cam plate 20. 20
18
16
288960
9803/6030 Issue 1
92 - 7 Slew Motor 92 - 7
Assembly (cont’d)
6 Mount The inner ring E of the taper roller bearing 1 on F
the cylinder 16 by hand and press using a press fitting
jig F. 1
Note: The end face of the cylinder should be protected by a E

soft cloth to prevent it from being damaged while pre fitting.
16
288970
7 Apply a thin coat of JCB Retainer G where the inner

ring is mounted on motor output shaft 16.
G
16
288980
8 Mount the inner ring 22 on the cylinder 16 using a

press fitting jig F.
Wipe off excess sealing material spilled between the

F
inner ring 22 and the taper roller bearing.
22
16
288990
9 Mount the outer ring 1 of the taper roller bearing into the
housing 21. 1
21
289000
9803/6030 Issue 1
92 - 8 Slew Motor 92 - 8

16
Assembly (cont’d)
10 Apply grease to the lip of the oil seal. Hold the end of
cylinder 16 by hand and carefully insert the cylinder
assembly into housing 21. Use the seal protector on the
splines.
Note: The splines of the cylinder assembly protrude beyond

the housing, so use a guide of 30-50 mm (1.2-1.9 in) on the 21
lower part of the housing. Verify that spring 17 is inserted
correctly into the back face of retainer 19.
289010
Confirm that the cylinder end is approximately 7.5 mm
(0.3in) lower than the housing.
11 Mount friction plate 4 and mating plate 5.
Note: Apply hydraulic oil to both faces before mounting the 5

plates.
4
21
289020
12 Mount 'O'-ring 30 in housing 21 and 'O'-ring 6 on

piston 15.
6
Note: Grease the 'O'-rings before mounting.
15
30
21
289030
13 Apply hydraulic oil to the sliding surface around piston

15 and slide it into housing 21.
15
Note: It is difficult to insert piston 15 into the housing due to
O'-rings 6 and 30. Hold the piston 15 horizontally and push
it into the housing with one movement.
21
289040
9803/6030 Issue 1
92 - 9 Slew Motor 92 - 9

14
Assembly (cont’d)
14 Insert the brake unit springs 14 back into brake piston 15.
Note: Insert the springs 14 the same order as they were found
during dismantling. 21
289050
15 Mount the bushings 11 with Teflon rings 13 and the plate

springs 12 and the balance plate 7 into the bushing holes
in cover 28. A, B PORT SIDE 7
Note: Apply a coating of grease to the end faces and 11

peripheries of the bushings 11 and to the Teflon rings 13 13
before mounting them, as this helps prevent them from falling
out when the cover is mounted onto the housing. 12
When assembling balance plate 7 and cover 28, confirm

alignment marks on the mating faces to facilitate RELIEF SIDE 28
reassembly.
289070
16 Press needle bearing 3 inner ring into cover 28 and attach

snap ring 2.
2
28
289080
17 Apply grease to the 'O'-ring and install 'O'-ring 8 to cover

28.
28
288660
9803/6030 Issue 1
92 - 10 Slew Motor 92 - 10

Assembly (cont’d)
18 To prevent oil leakage from the cover bolt holes

apply JCB Multi-gasket H to the mating surface of
the housing 21 and the cover 28.
21
H 289090
19 Lift the cover 28 and the balance plate 7 by hand

and mount them carefully on the housing 21. 28
Take care that the balance plate 7 and bushings do

not fall out while mounting cover 28. Align housing
21 and cover 28 alignment marks which were made
before dismantling.
21
289100
20 Tighten the bolts 34 (with 10mm A/F hexagonal

socket) which attach the cover 28 to the housing 21
to a torque of 103 Nm (76 lbf ft.). 34
28
21
289110
21 Tighten and insert the relief assemblies 23 with a

27mm A/F hexagonal socket) into the cover 28 to a 31
torque of 39 Nm (29 lbf ft.).
Tighten and insert the by-pass valve assemblies 31

(with 8mm A/F hexagonal socket) into the cover 28
to a torque of 39 Nm (29 lbf ft.).
23
28 289120
9803/6030 Issue 1
92 - 11 Slew Motor 92 - 11

Assembly (cont’d)
22 Final checks after assembling.
Open the inlet and outlet ports and apply 39.2 bar (40
kgf/cm2)(569 lbf/in2) pilot pressure to the brake release
port. (Take care as oil will be discharged from the drain
port). Check that the drive shaft can be rotated
smoothly for at least one full revolution by applying a
torque of approx. 24.5 Nm (18.0 lbf ft).
Note: If the shaft does not turn, the unit has not been
assembled correctly so dismantle again and inspect.
9803/6030 Issue 1
95 - 1 Slew Motor 95 - 1
Fault Finding
Table 1.
Symptom Cause External Inspection Countermeasure Repair

Internal damage to the Measure the oil drain High possibility of Refer to Table 2.
motor. volume. damage to the sliding
surfaces if the supply
volume is approximately
equal to the drain
volume. Dismantle and
Motor does not run
inspect.
Internal damage to the Open the motor inlet and High possibility of Renew damaged parts
motor. outlet ports and apply internal damage to the or renew the motor
39 bar (40 kgf/cm2 ) motor if the supply shaft assembly.
(569lbf/in2) pilot pressure to does not rotate smoothly
the brake release port. when this torque is
Try to rotate the shaft with applied. Dismantle and
a torque of approx. inspect.
24.40 Nm (18 lbf ft).
Relief valve in circuit not Measure pressure. Reset to the prescribed
set correctly. setting.
Wear or damage to the Measure the oil drain Leakage is too high if the Refer to table 2.
Excessive slip
motor sliding surfaces or volume. oil drain volume exceeds

to the high-pressure seal. 5 l/min (1.1 gal/min).
Dismantle and inspect.
Oil hot and excessive Measure the oil Reduce the oil Refer to table 2.
leakage in the motor. temperature. temperature.
Seizure of motor sliding Check for any metallic If metallic matter is Repair or renew the
parts or circuit. matter deposited in motor discovered or the supply damaged parts. Renew
Abnormal heating
drain oil or drain filter. shaft does not rotate the motor assembly.
Apply a 39 bar (40 kgf/cm2) smoothly when torque is
(569 lbf/in2) pilot pressure applied, there is a high
to the brake release port possibility of internal
and try to rotate the shaft damage to the motor.
with a torque of approx. Dismantle and inspect.
24.40 Nm (18 lbf ft).
Damage or wear to oil Renew the oil seals.
seal lip.
Leakage from oil seals
Damage or wear of the Repair the problem or

shaft seal. renew the motor
assembly.
9803/6030 Issue 1
95 - 2 Slew Motor 95 - 2
Fault Finding (cont’d)
Symptom Cause External Inspection Countermeasure Repair

Wear or seizure of the Open motor inlet and High possibility of Inspect the parts and
motor sliding surfaces. outlet ports and apply 39 bar internal damage to the bearing according to
40 kgf/cm2 (569 lbf/in2) motor if the supply shaft Table 2 a-e and renew
pilot pressure to the brake does not rotate smoothly any defective parts.
release port.Try to rotate when this torque is
Insufficient torque
the shaft with a torque of applied. Dismantle and

approx. 24.40 Nm inspect.
(18 lbf ft).
Relief valve in the circuit Measure relief pressure. Reset to the prescribed
is not set correctly. setting.
Internal damage to the Check if any metallic High possibility of Repair or renew
motor. matter is deposited in the internal damage to the damaged parts. Renew
motor drain oil or drain motor if metallic matter the motor assembly.
filter. is discovered.
Dismantle and inspect.
Large amount of air Check the oil in the tank Thoroughly bleed the air.
Abnormal noise
mixed in the oil. and motor casing.

Loosening of bolts or Check if the piping Tighten to the specified
pipes connections, attachment torque.
mounting bolts, motor
attachment bolts or other
bolts are loose.
O-ring is damaged Renew O-rings.
Oil leakage from
mating surfaces
Seal face is damaged. Repair seal face or

renew.
Bolts are loose. Check the bolt tightness. Tighten the bolts to the
correct torque.
Table 2.
No. Part Inspected Repair

a Wear of the sliding surface of balance plate 7. Repair or renew the part
b Damage to sliding surface of cam plate 20. Repair the part or renew the motor.
c Damage to sliding surface of the piston assemblies 18. Repair the part or renew the motor.
d External wear to the piston assemblies 18. Repair the part or renew the motor.
e Wear to piston bores in cylinder assembly 16. Renew the motor.
f Damage to Teflon ring 13 . Renew the part.
9803/6030 Issue 1

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Section E Hydraulics Section E

Contents Page No.

Pressure Testing 4-1

Fault Finding 5-1

Machine Valve Location 25 - 1

Remote Control Valve (Services)

Pilot Supply Valve

Contents Page No.

Schematic, Hydraulic Circuit

BOOM CYLINDER ARM CYLINDER

305 305 305 305 305 305 1

26 2.5Bar TRAVEL(L) TRAVEL(R)

EC PILOT T E e f g h i j BACKWARD FORWARD FORWARD BACKWARD

305 305 305 305 305 305 1

EC PILOT T E e f g h i j BACKWARD FORWARD FORWARD BACKWARD

Control Valve - Spool in Neutral (Arm/Boom/Bucket/Offset)

Control Valve - Spool in Neutral

A High pressure feed

When the spool is in the neutral position (no service

3 The oil supply to port P also flows through the neutral

Control Valve - Single Spool Operation

RETURN FROM SERVICE

Control Valve - Single Spool Operation

A High pressure feed

1 When the single service is selected (the arm is used

a The oil from the neutral gallery flows through the

b Oil flows to the compensator and, with the

c Oil will also open the compensator check valve and

d The oil in the L/S line can also be seen at the

b On the second path the oil crosses the spool and

Control Valve - Two Spool Operation - Multi Functioning

Control Valve - Two Spool Operation -

Travel Operation - Low Speed DOZER RAM

TRAVEL MOTOR LH TRAVEL MOTOR RH

A High pressure feed

Travel - Low Speed

Travel - High Speed

The only difference between low and high-speed travel is

100% Swing Brake

X Swing Brake Solenoid

Y Swing Lock Solenoid

100% Swing Brake

a When 100% swing brake is required then the swing

50% Swing Brake

X Swing Brake Solenoid

Y Swing Lock Solenoid

50% Swing brake

a 50% swing brake is achievable by having the swing

A High pressure feed

a When swing is operated the swing brake and swing lock

Cross Line Relief Valve

2 Swing acceleration, during swing (Figure 2) Figure 1

3 Swing Braking (Figure 3)

Because there is no close of pressure between port H E

The oil from the spring chamber on the back section of

Swing Reduction Gear Oil Recycling

To aid maintenance, the drain oil from the motor section